Manual Overhead Conveyors

High-performance. Flexible. Future-proof.

Targeted Material Flow via Manual Overhead Conveyor Systems

Our manual overhead conveyor systems provide a cost-effective means to optimize internal transport routes. They comprise a robust rail system with trolleys, enabling manual guidance of loads.
Their deployment facilitates a targeted material flow within the facility and significantly reduces the physical strain on your personnel.

With a load capacity ranging from 500 to 2,000 kg, our systems provide the ideal solution for assembly workstations, production lines, and logistics areas. Whether for manual operation or semi-automated configurations, we adapt the technology flexibly, ergonomically, and reliably to your specific processes.

Thanks to diverse expansion options, the system can be individually configured. Our solutions are characterized by maximum flexibility, robust construction, and simple, intuitive operation. This approach enhances both efficiency and process reliability – now and for the future.

System Overview

A manual overhead conveyor system is a manually operated conveying system designed for the horizontal and, in some cases, vertical transport of loads, utilizing an overhead-mounted rail structure.

Typical Applications

Assembly Workstations
Production Lines
Workshops
Logistics and Picking Areas
Production Lines with Manual Material Flow

System Components

Manual overhead conveyor systems typically consist of the following components:

load-bearing rail profiles
trolleys or carriages
load handling attachments such as traverses, hooks, or fixtures
optional switches, turntables, or transfer carriages

All transport movements are performed by the operator's manual force, without motor drives.

System Functionality

The load is suspended from a trolley within the rail. The operator guides the load by precisely moving the trolley.

Movement Modes

Longitudinal movement
Diverting to other tracks via switches
optional lifting or lowering via hoists

Examples include spring balancers, tool balancers, manual chain hoists, or automatic lift/lower stations.

Effortless Movement

Movement is exceptionally effortless, as the trolleys are typically equipped with suitable components for low-friction operation.

ball-bearing rollers
low rolling resistance
optimized rail profiles

Normal Operation

As manual overhead conveyor systems are operated exclusively by hand, there are no electrical operating modes. Nevertheless, various usage scenarios are distinguished in daily operation.

Manual Conveyance

Moving the load by pulling and pushing the trolleys
Guidance along the rail or through switches
Transport at ergonomic speed
all movements unpowered

Operation with Hoists

If balancers, spring balancers, manual chain hoists, or lift/lower stations are integrated, additional movement sequences arise.

Manual Lifting and Lowering
Automatic Lifting and Lowering
Load remains guided by the trolleys

Safety Instructions

Manual overhead conveyor systems are considered safe. Nevertheless, the following rules must be strictly observed for reliable operation:

The permissible load capacity of the system and the trolleys must not be exceeded.
Only trained personnel are permitted to operate the system.
The load must not be swung or moved over personnel.
Strong jerking or striking of the load must be avoided.
Hands must not get caught between the trolley and the rail.
Visual contact with the load is always required during transport.

Safety always takes precedence over speed. Loads must only be moved in a controlled manner and with adequate oversight.

Engaging the Load

Ensure that the system is freely accessible.
Position the trolley above the load.
Secure load handling attachments, such as hooks or spreaders, correctly.
Verify that the load is securely suspended and all safety latches are engaged.

Conveyance Along the Track

Move the trolley smoothly.
Avoid abrupt movements.
Maintain a controlled speed, adjusted to the operational environment.

When Traversing a Switch

Operate the switch.
Guide the trolley into the new direction.
Continue controlled movement.

Lowering the Load

Lower the load slowly and in a controlled manner, provided a hoisting device is available.
Release the load attachment.
Unload the trolley and move it to the parking position.

Special Notes

For extended distances or heavy loads, transport should be performed by two operators.
Switches and transfer points must be regularly inspected for smooth operation and proper locking.
In the event of unusually high rolling resistance, the system must be inspected immediately.
Never leave loads permanently suspended on the track unless explicitly designed for such an application.

Maintenance and Inspection

Regular maintenance ensures safe and reliable operation. This specifically includes the following measures:

Visual inspection of the rails for wear or damage.
Inspection of trolleys and rollers.
Functional testing of switches.
Verification of fastening points on the supporting structure.
Lubrication of running rollers, if specified by the manufacturer.
Inspection of all load handling attachments.

Technical Note

Maintenance work may only be performed by qualified specialist personnel.